Stackable Cast Stone Composite Fermentation and Storage Tank

ABSTRACT

A liquid storage vessel having a base with a bottom and an interior floor; a continuous side extending vertically from the base and having an interior surface, the bottom and continuous side each including an internal layer and an external layer separated by a material barrier and configured such that the interior layers form an inner containment liner, and the external layers form a continuous exterior structural shell enclosing the inner containment liner. A top is affixed to the continuous side and has an interior ceiling. Access to the tank interior is provided by one or more manways. Mounting and connecting structures enable the tanks to be stacked directly atop one another and then structurally connected. The exterior structural shell is fabricated from high performance fiber reinforced concrete, and the inner containment liner is fabricated from a geopolymer concrete blend.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/465,986, allowed, which was the U.S. National Stage (371)application filed under 35 U.S.C. § 371 based on International Appl. No.PCT/US17/64321, filed 1 Dec. 2017, which was based on U.S. ProvisionalPatent Appl. Ser. No. 64/429,015, filed 1 Dec. 2016.

BACKGROUND OF THE INVENTION Technical Field

The present invention relates to food and beverage storage containers,and more particularly to wine and beer storage tanks, and even moreparticularly to a concrete storage tank having a two-layered compositewall structure with an interior layer fabricated with a materialformulation that enhances the performance of the vessel as a food andbeverage storage tank but does not impart undesirable flavors into thestored liquid nor in any other way adversely affect the food or beverageproduct, and an exterior layer fabricated with a fiber reinforcedcementitious material designed for structural stability and foreffectively containing internal atmospheres.

Background Art

The use of concrete and fired clay ceramic containers for water storage,wine fermentation, and wine storage, is well known in the art. Theancient Georgians were the first to use clay vessels for wine in circa6000 BCE. Egyptians are known to have used fired clay amphoras as earlyas 2000 BCE. Ancient Rome used the clay amphora and wooden vats for winefermentation, and the first wooden barrel for wine transportation in 50CE, and later in the first century CE the Romans were the first to useconcretes that contained a hydraulic and pozzolanic type cement for winefermentation and storage.

Concrete quickly became and remained the first choice for large volumewine fermentation and storage because of the ready availability of itsraw materials and because of its property of having a large thermalmass. That large thermal mass maintains a consistent storage temperaturefor wine.

By contrast wood barrels were primarily used for transportation.However, they were also used for fermentation and storage where suitablewood was plentiful. Stainless steel tanks were not used in wineproduction until the 1960's, but thereafter they quickly became thedominant material in commercial wine production globally because oftheir durability and lower maintenance requirements.

Ceramics, and more particularly kiln fired clay ceramics, are by naturemore chemically inert than Portland cement mortar and/or concrete aswell as non-kiln fired clays. But kiln fired ceramics require extremelyhigh temperatures and therefore result in extremely high costs for largeunits. Such a process is entirely incompatible with the compositestructure of the present invention.

Low temperature geopolymer formulations, also known as raw ceramicsand/or alkali activated binders, are well-known in the art. Theseformulations generally comprise dry earth components including aluminumsilicate materials, most often derived from industrial waste fly ashmaterials. Less frequently they are formulated using natural pozzolanicclay, and still less frequently using calcium carbonate materials. Thedry earth components are typically combined with a high alkalinesolution consisting of sodium silicate and sodium and/or potassiumhydroxide as an activator to form a ceramic polymer that does notrequire the high temperatures employed in the kiln firing of ceramics.Raw ceramic geopolymers are usually combined with aggregates to makemortars and concretes.

High performance geopolymers—that is, more chemically inert geopolymersand fired clay ceramics in general—are known for their higher chemicalinertness and their durability, holding up extremely well toenvironmental conditions that typically cause material degradation. Lowtemperature, high performance geopolymer mortar and concretes aretypically more acid resistant than Portland cement mortars andconcretes. However, low temperature; high performance geopolymerstypically have a high fly ash content, which is considered a toxic wastematerial. This is due to the fact that they typically have a high heavymetal content.

Geopolymers comprising dry earth materials other than fly ash andgeneral kiln ashes—materials such as uncalcined, aluminosilicateclays—are not considered “high performance” geopolymers in the industrybecause they have a higher water demand and a higher organic content,which results in lower compression strength, more chemical reactivity,and less acid resistance. Therefore, most geopolymer development hasbeen concentrated in the use of industrial waste fly ashes. Theconsequence is that the most common application for geopolymers has beenas a substitute for Portland cement in the fields of toxic wastecontainment and concrete waste pipe manufacturing. Accordingly, thoseskilled in the art would not consider using a geopolymer chemistry for awine or food storage container.

Background Discussion Regarding Wine Industry Applications: Currently,the pH of premium wines ranges between pH 3 and pH 4. Wines with a lowerpH tend to taste fresher, more tart, and they age longer with lesslikelihood of spoilage. Wines with a higher pH tend to taste flat andoxidize at a higher rate, and they are more susceptible to microbialspoilage.

The dissolved oxygen content of premium wines ranges between 5 to 8 ppm.Levels above 8 ppm of dissolved oxygen in wine are considered excessoxidation or oxygen saturation and can elevate pH levels and result inspoilage. Dissolved oxygen amounts lower than 5 ppm results in asub-premium wine.

Conversely, in wine fermentation, available oxygen is important andbeneficial to initiate and maintain the fermentation process. Oxygendemands and benefits decrease as the fermentation cycle matures, yet asthe fermentation cycle continues, temperature control becomes essentialto sustain and complete proper fermentation.

The wine industry has come to recognize the benefits that early caststone vessels provided in wine making history. Not only did the porosityof the cast stone vessels give them a greater surface area, they had aconsiderable thermal mass, and thus more temperature stability. Theancient practice of using stone vessels, long ignored and largelyforgotten, has been resurrected. There is now a developing trend inpremium wine production to return to the use of cast stone and ceramicvessels, again owing to the influence of surface porosity and thermalmass. However, this new trend is limited substantially to thefermentation process.

Portland cement is a hydraulic binding cement classified by the ASTMinto six different types: Types I-V, and ordinary white Portland cement.All types are variations on the tricalcium silicate chemistry ofPortland cement. Type I is considered general purpose; type II has amoderate sulfate resistance; type III has high early strength; type IVis a slow reacting; type V has high sulfate resistance; and white cementis considered decorative and similar to type I. Types I and II Portlandcements are the most commonly used and type II is often blended withtype V. Therefore, types I and II by themselves, and the blend of typeII and V will be referred to hereafter as “Standard Portland cement.”

Fermentation tanks made of Standard Portland cement concretes have analkalinity of 10 to 11 pH, and the high surface area contact of theporous concrete surface reacts with the acidic wine (pH of 3 to 4) tocreate a vigorous ionic exchange between the concrete and the wine. Thisprovides available oxygen for the early part of the fermentationprocess. The oxygen production falls off as tartrates accumulate on theconcrete surface, forming a quenching barrier between the pHdifferentials. The proliferation of yeast cycling to sugar and then toalcohol in the fermentation process consumes the surplus oxygen from theinitial pH reaction, rendering a stable oxygen and pH level. Thus, thedissimilar chemistries between the wine and the standard Portland cementconcretes lend themselves beneficially to the fermentation process.Furthermore, the thermal mass of a concrete tank benefits the control oftemperature for optimal results. The benefits mentioned above are notrealized in the stainless steel and/or plastic fermentation tankscommonly used in the industry today.

However, the benefits deriving from the dissimilar chemistries inpremium wine production using standard Portland cement concretes are notwithout a considerable cost, inasmuch as they result in the slow butsteady decomposition of the concrete; so the useful life of StandardPortland cement vessels are limited. Regardless of the noted benefits ofPortland cement concrete in fermentation, and even knowing the longhistory of hydraulic/pozzolanic cement concrete use in wine storage,because current day standard Portland cements react with acidic wines,and decompose as a result, standard Portland cement concrete is not thebest choice for long term wine storage involving sustained exposure towine.

Wine storage and pre-bottle aging is the last step in the wine makingprocess, coming after the blending and fermenting of the grape juice tomake the wine, and before bottling. In today's wine industry there is anincreasing concern over the control of dissolved oxygen and pH levels inthe pre-bottle storage and aging steps. This is because higher levels ofoxygen exposure are nearly unavoidable in the bottling process, and anyaddition of oxygen to the liquid will only contribute to the totaldissolved oxygen content of the bottled wine and thus the potentialspoilage of the wine. This is the principal reason that long term winestorage in tanks made from Portland cement concrete has been limited toextremely large volumes of sub-premium wines in extremely large tanks,wherein the ratio of the surface area of the tank to the volume of thewine is smaller and therefore has less of an adverse impact.Furthermore, there is a trend in the United States Food and DrugAdministration to more closely monitor the production of wine and tomandate more sanitary conditions for wine storage. Accordingly, thoseskilled in the art have not considered using low volume cast stone winestorage containers, whether made of Portland cement or geopolymericconcrete.

DISCLOSURE OF INVENTION

The present invention is a stackable, long-term food and beveragestorage vessel especially well-suited for wine storage. The vesselincludes a two-layered composite wall structure having an interior layerwith interior surfaces fabricated with a composition advantageous forfood and beverage storage by not imparting undesirable flavors into thestored liquid, and with an exterior layer fabricated with afiber-reinforced concrete material that greatly enhances the structuralstability of the vessel to effectively contain internal atmospheres.These benefits are highly desirable in wine storage and aging but applyequally well for the production and storage of many other beverages andfoods.

The inventive vessel further provides a stackable storage unit with ahigher thermal mass than the oak barrels and stainless steel tankscurrently employed in the food and beverage (wine) industries. Thehigher thermal mass is better for maintaining consistent temperatures ofthe stored product. Due to its material formulations, it also provides aporous interior stone surface area that does not react adversely withacidic wines, either by corroding or undergoing other reactions thatcause material decomposition. The vessel thereby provides a longlasting, low maintenance surface that does not contribute to anundesirable elevation of wine pH and dissolved oxygen levels in a vesselthat optimizes thermal stability.

In a preferred embodiment of the present invention the interior side ofthe composite tank is composed of a geopolymer concrete. The geopolymerconcrete includes dry earth components, silica sand, and water. The dryearth components of the geopolymer include a unique blend of naturalclay, carbonates and pozzolans, and industrial waste materials chosenfor their distinct strength development characteristics, minimal organiccontent, minimal loss on ignition (LOI) and minimal heavy metal content.The alkaline reactive components include sodium silicate, sodiumhydroxide potassium hydroxide, colloidal silica, and solutions ofinorganic alkaline salts, The geopolymeric binder further includesspecific amounts of hydrophilic crystals, and tartaric acid salts.

In another embodiment the interior side of the composite tank iscomposed of concrete comprising specific blends of cements, SCM's(supplementary cementitious materials) and performance supplements inspecific ratios. The cements in the blend are chosen from a group ofhydraulic, pozzolanic and refractory cements, including specificPortland cement types, calcium aluminate, aluminum phosphate, andmagnesium phosphate cements, and the SCM's are chosen from a groupincluding; blast furnace slags, ultra-fine fly ash, natural pozzolans ofspecific particle sizes and ground fired clay bisque. The performancesupplements include hydrophilic crystals, colloidal micro silica, andsolutions of inorganic alkaline salts. All components are chosen eitherfor a low heavy metal content and/or a chemical contribution for acidresistance.

In embodiments the interior sides of the vessels are more chemicallyinert than Standard Portland cement concrete and possess a substantiallynon-reactive stability when directly exposed for sustained periods oftime to extreme chemistries or pH disparities, such as those found inthe storage of wine.

Further, in an embodiment the present invention also relates to astorage vessel structure that includes a combination of two differentmaterial layers comprising the tank envelope. The layers optimizestructural and functional performance as a wine storage vessel. Thelayered structure consists of a novel blended cement or geopolymerconcrete formula on the interior of the tank envelope and a GFRC (glassfiber reinforced concrete) structural shell on the exterior of the tankenvelope. The composite nature of the vessel envelope, having a highdensity concrete on the interior and the high flexural strength of aglass fiber reinforced concrete on the exterior, eliminates structuralfaults on the interior portions of the composite envelope fromtelegraphing to the exterior to more effectively contain internalatmospheres and substantially eliminate the potentials for leaks. Theinternal conditions of the composite benefit the development and storageof fermented beverages, including beer and wine, as well as foodproducts.

In addition, the inventive vessel design substantially eliminatesatmospheric head space that may include air pockets above the storedproduct, thereby minimizing product spoilage due to oxygen exposure.

The vessel design facilitates unit-on-unit (tank-on-tank) stacking aswell as transport by forklift. At the same time, the vessel designprovides structures to facilitate access to stored product for testing,sampling, and the insertion of flavor submersibles and environmentalcontrol devices, all of which are incorporated into the design so thatthey are accessible after units have been stacked.

It is an object of the present invention to provide a long-term winestorage vessel for storing wine in a cast stone material havingsubstantially lower heavy metal content than typically found in knowncast stone materials. Embodiments of the present invention have a lowerheavy metal content than that found in Standard Portland cementconcretes, and a lower heavy metal content than is typical in lowtemperature, high-performance geopolymer concrete.

It is a further object of the present invention to provide a long-termwine storage vessel wherein the material formulations and the compositedesign provide optimal control of the temperature, oxygen content and pHlevels of the stored food and beverage product.

It is yet another object of the present invention to provide along-term, stackable wine storage vessel wherein the wine (storedproduct) is contained in a cast stone composite container that does notleak and costs less per volume than oak barrels and fired clay ceramicvessels.

Embodiments of the present invention include several novel features,among which are the following:

(1) Geopolymer formula: A geopolymer formula with low heavy metalcontent for use in a food grade storage vessel. The geopolymer formulacast in mortar cubes achieves three day compression strengths between3000 and 9000 psi, seven day strengths between 4000 and 10,000 psi, and14 day strengths between 5000 and 11,000 psi.

Geopolymer blend (formula) #1 (geopolymer blend #1) below has 20% to 60%less heavy metal content than published Portland cement averages.

Geopolymer blends (formulas) #1 and #2 below have 50% to 80% less heavymetal content than typical fly ash averages. [See the table of FIG. 13,240]

Mortar cubes made from the embodiment of formula #1 have been shown tolose 40% less mass than standard Portland cement mortar cubes insustained exposures to tartaric acid wine solution with a pH range of3.3 to 4.1, as expressed in the table of FIG. 12D.

Mortar cubes made from the embodiment of formula #2 have been shown tolose 59% less mass than standard Portland cement mortar cubes insustained exposures to tartaric acid wine solution with a pH range of3.3 to 4.1, again expressed in the table of FIG. 12D. The controls andthe inventive geopolymer blend cubes were all cast as 2″×2″×2″ cubes andcured at 120 to 160 degrees F. for 24 hours. They were then tested andanalyzed at 14 days.

In the sustained exposure testing expressed in the tables of FIGS.12C-12D; formulas #1 and #2 elevated the pH of the tartaric acid winesolution 0.4 to 0.7 pH less than the standard Portland cement cubes and0.1 pH less than the fly ash base geopolymer control cubes.

(2) A specific blend of hydraulic, pozzolanic and refractory cements,binding activators, and SCM's formulated for low acid reactivity, lowpermeability and low heavy metal content.

(3) Composite wall design: The walls of the storage vessel are a binarycomposite comprising a structural outer layer and a generally chemicallyinert inner containment layer. The outer layer is a high performanceGFRC (glass fiber reinforced concrete) that provides an exteriorstructural shell of high flexural, tensile, and compression strengths.The high strength is due, in part, to integral additives well known tothe art. The structural exterior shell has no contact with the storedproduct (wine or food). It may be pigmented and sealed with penetratingand/or topical sealers and finishes such that the GFRC exterior doublesas a decorative outer shell.

The binary envelope of the composite design also includes an interiorcontainment liner of a particular cast stone concrete which provides asubstantially chemically inert surface area engineered for directcontact with the wine (stored food product). The benefits of thiscomposite design and the synergy of its binary parts collectivelyprovide a storage vessel that is highly resistant to cracking andleaking. Furthermore, the design substantially increases the containmentof atmospheres and therefore significantly enhances the ability tocontrol oxygen levels, which is critically important to wine storage andaging.

(4) General Design: The inventive storage vessel is designed to achieveseveral novel features, including:

(a) elimination of head space: One of the primary achievements of thegeneral design was to eliminate dimensional head space above the beer,wine, or stored food product.

(b) stackability: Another objective of the general design was tofacilitate both forklift mobility and unit stacking.

(c) Access and Control of Stored Product: Another object of the generaldesign was to facilitate access to the stored product, even when unitsare stacked. Access ports for filling, sampling, pumping-over andracking remain accessible after units are stacked. Access ports alsoaccommodate technical monitoring devices, including level sensors fortopping off head space and monitoring product loss, an oxygen sensor, apH monitor and temperature sensor and sleeves for flavor submersibles.

(5) The fifth novel characteristic resides in the formula for making thevessel structure, as set out in the detailed description that follows.

(6) Lower cost alternative: Another primary goal of the presentinvention is to provide a low volume storage vessel that provides thebenefits of high thermal mass in a stackable unitary design that willlast significantly longer than oak barrels and thus to provide a lowercost alternative for stackable wine storage.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1A is an upper right front perspective view of an embodiment of thestackable geopolymer-based fermentation and storage vessel of thepresent invention;

FIG. 1B is the same view showing a top side manway partially opened;

FIG. 2 is a front view in elevation of the vessel of FIG. 1A;

FIG. 3 is a right side in elevation thereof, showing interior featuresin phantom;

FIG. 4 is a top plan view thereof;

FIG. 5 is a cross-sectional side view in elevation, showing a pluralityof flavor imparting oak staves suspended from the top manway;

FIG. 6 is a rear view in elevation of the vessel of FIG. 1A;

FIG. 7 is a cross-sectional side view in elevation thereof;

FIG. 8 is an upper left perspective view showing two sets ofunit-on-unit stacked vessels;

FIG. 9 is a front right cross-sectional view showing the interiorfeatures and sensor system of an embodiment of the vessel;

FIG. 10 is the same view showing oak staves suspended from the topmanway;

FIG. 11 is an embodiment of a visual map showing data gathered fromsystem sensors disposed in the stacked vessels in a wine productioncellar;

FIG. 12A is a table comparing the compression strength of two novelgeopolymer blends employed in embodiments of the storage vessel of thepresent invention with the compression strength of a Portland cementcontrol and a fly ash geopolymer control;

FIG. 12B is a table comparing pH elevations in wines stored long term invessels having interior walls composed of the geopolymer blends of thepresent invention against the above-identified controls;

FIG. 12C is a table showing pH elevations in tartaric acid winesolutions at a beginning pH of 3.3 and comparing the elevations insolutions stored in the vessels of the present invention as against theabove-identified controls;

FIG. 12D is a table showing mass loss for mortar cubes made from thegeopolymer formulas used in the present invention as against mass lossin identically sized mortar cubes made from standard Portland cement anda control fly ash geopolymer after sustained exposures to tartaric acidwine solution with a pH range of 3.3 to 4.1; and

FIG. 13 is a table showing the heavy metal content of the geopolymerblends of the present invention as compared to the heavy metal contentof standard Portland cement and a fly ash geopolymer.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring first to FIGS. 1 through 11, wherein like reference numeralsrefer to like components in the various views, there is illustratedtherein a new and improved stackable geopolymer-based fermentation andstorage tank, generally denominated 10 herein.

FIGS. 1-4, 6-9 illustrate an embodiment of the stackable cast stonefermentation and storage vessel as described herein. Collectively, theseviews show that in an embodiment the vessel may be generally cuboid inshape, perhaps having a height dimension slightly exceeding its widthand depth dimensions. For both structural and ornamental purposes, thesides may include a slight outward medial (belly) bulge, therebyproviding an elegant departure from a tedious and exclusivelyutilitarian straight-line geometry.

In an embodiment, the vessel includes a front side 12, a right side 14,a left side 16, a rear side 18, a top 20, a bottom 22, all formingcontiguous and continuous walls, both interiorly and exteriorly. A base24, of which the bottom 22 is an integral part, is disposed under thevessel bottom and has spaced apart pairs of right and left legs 26, 28,respectively, defining a space 30 under the vessel to accommodate theforks of a forklift. For added structural integrity, the legs may bereinforced with deformed welded wire mesh (not shown, but known in theart).

The vessel further includes a top manway 32 and a sidewall manway,preferably a front side manway 34, providing access to the vesselinterior. The top manway 32 includes a stainless steel circular manwaycover 36 coupled to a bracket (or swing arm) 38 to provide a hygienicclosure when clamped tightly in a closed position. The closure includesan open-toe clamping assembly 40 which has a swing bolt assembly 42 atthe outboard end of the bracket so that the swing bolt can be pivotedout of the open toe of the bracket 38. The opposite end 46 of thebracket 38 is pivotally coupled to the vessel top on a pivot pin 46 sothat when the swing bolt is loosed and removed from the bracket, themanway cover can be slightly lifted and then opened by swinging(pivoting) the cover away from the manway opening. In this way, themanway cover is pivotally attached to the top in such a way as to pivoton a horizontal plane onto and away from the manway hole. Thus, accessto the vessel can be achieved even when there is little clearance abovethe vessel, such as when it the lower vessel in a stacked configuration(see, esp. FIG. 1B).

Small cylindrical access ports 50, 52, may be provided at the front ofthe vessel for installing product sensors, introducing a sampleextractor (such as a wine thief), or for adding or removing product fromthe vessel interior. The ports may be capped when not in use.

Coupling elements, such as upper and lower embedded threaded receivers54, 56, respectively, may be disposed on the upper and lower portions ofthe vessel right and left sides to serve as anchor points and couplingplate connection points. These enable the vessel to be secured to thefloor with tie-down plates 58 and stacked upon one another with couplingplates 60.

Looking now at FIG. 3 in particular, it may be seen that the vesselfloor 62 (i.e., the interior side of the tank bottom) is sloped gentlytoward the vessel front so that liquids will fully drain through a drainport 64 disposed at the base and front of the vessel when so desired.The ceiling 66 (i.e., the interior side of the top) of the vesselinterior 68 slopes upwardly from the rear to the front, such that whenfilled with liquid to the ceiling, the access port is also filled to theedge of the vessel, thereby limiting oxygen exposure.

The top 20 of the vessel is bonded (e.g., with cement epoxy) to aperimeter ledge 70 formed in the contiguous front, right, rear, and leftsides of the vessel.

The walls of the vessel structure (front, sides, rear, top, and bottom)are a binary composite envelope comprising, first, an exteriorstructural outer layer of high performance GFRC (glass fiber reinforcedconcrete), wherein the bottom and side walls form a continuous andcontiguous exterior structural shell 72 of high flexural, tensile andcompression strengths. The exterior protective layer or shell ispreferably sprayed and consolidated in layers over the interiorcontainment liner, next described.

The binary composite envelope next includes an interior containmentliner 74 of wet cast concrete fabricated with one of the geopolymerconcrete formulas set out below. The outer and inner layers areseparated by a layer of fiberglass mesh 73 disposed between the exteriorstructural shell and the interior containment liner. Other types ofmaterial barriers may be employed to separate and segregate thestructural portions of the shell.

When employed in wine production, the shell may include penetrationsother than the above-identified access ports. For instance, an optionalracking port 76 may be included.

And referring now to FIGS. 7 and 9, in an embodiment a protective tube90 (stainless steel mesh) may be placed in one of the access ports so asto extend down into the stored liquid. A level sensor strip 92 and atemperature probe 94 may disposed in the protective tube and coupled toa sensor transmitter 96 having an internal circuit board and wifi radioantenna so as to transmit data concerning product conditions to areceiving system (e.g., a server computer). The server includes softwarethat provides a visual display 100 of the data by vessel location andpresents alerts 102 when product conditions warrant attention (see FIG.11).

In embodiments, the interior (inner containment) layer may have acomposition as follows:

Geopolymer Blend #1: (a) 1 part dry earth components dried and milledfrom 200 mesh to 450 mesh minus and chosen from specific sources for lowloss on ignition (“LOI”) and low heavy metal content, in the followingmineral descriptions in noted percentage ratios: (a1) 0-15% volcanicpumice; (a2) 0-15% diatomaceous earth/siliceous shale; (a3) 0-15%volcanic ash; (a4) 0-25% calcium carbonate; (a5); 0-50% silica; (a6)0-50% kaolinite clay; (a7) 0-20% fired clay bisque; (a8) 0-35% soda limeglass; (a9) 0-20% calcium sulfate hemihydrate; (a10) 0-20% lime kilndust; (b) (0.4-0.6 parts) alkaline reactive components, comprisingspecific base solutions selected from: (b1) 60-80% sodium silicatesolution 40-60% solids, and (b2) 20-40% sodium and/or potassiumhydroxide solution 40-60% solids; (c) (1-2 parts) silica sand; and (d)(0.2-0.3 parts) water.

In an alternative blend, referred to herein as geopolymer blend #2, thecomposition may include the following:

Geopolymer Blend #2: (a) 1 part dry earth components dried and milledfrom 200 mesh to 450 mesh minus and chosen from specific sources fortheir low LOI and 9 out of 14 of the following components chosen fortheir low heavy metal content; in the following mineral descriptions innoted percentage ratios: (a1) 0-10% volcanic pumice; (a2) 0-10%diatomaceous earth/siliceous shale; (a3) 0-10% volcanic ash; (a4) 0-25%calcium carbonate; (a5) 0-20% silica; (a6) 0-40% kaolinite clay; (a7)0-10% fired clay bisque; (a8) 0-20% soda lime glass; (a9) 0-10% calciumsulfate hemihydrate; (a10) 0-20% lime kiln dust; (a11) 0-30% type F flyash; (a12) 0-20% type C fly ash; (a13) 0-25% rice hull ash; (a14) 0-10%blast furnace slag; and (b) (0.4-0.6 parts) alkaline reactivecomponents, comprising specific base solutions selected from: (b1)60-80% sodium silicate solution 40-60% solids; (b2) 20-40% sodium and/orpotassium hydroxide solution 40-60% solids; (c) (1-2 parts) silica sand;and (d) (0.2-0.3 parts) water.

The properties and performance characteristics of mortar cubes made fromthe foregoing two geopolymer blends (formulas #1 and #2) were comparedto the properties and characteristics of mortar cubes made from twocontrols, including one made from a fly ash geopolymer and the otherfrom standard Portland cement. The test and fly ash control cubes werecast in cubes measuring uniformly two inches on each side and were curedat 120 to 160 degrees F. for 24 hours. They were tested at 14 days. Thestandard Portland cement control cubes were identically sized cubes andcured using an ASTM industry standard 27-day cure and subjected totesting at 27 days. Test results are shown in the tables of FIGS.12A-12D, 200, 210, 220, and 230, respectively.

The control cube compositions included the following:

Fly Ash Geopolymer Mortar Cube: (a) 1 part dry earth componentscomprising: (a) ASTM C618 compliant SCM's of the following industrialwaste material descriptions in the ratios of 67% Class F fly ash and 33%Class C fly ash; (b) 0.4-0.6 parts alkaline reactive components,comprising specific base solutions selected from 60-80% sodium silicate40-60% solids, and 20-40% sodium and/or potassium hydroxide 40-60%solids; (c) 1 to 2 parts silica sand; and (d) 0.1 to 3 parts water.

Standard Portland Cement Mortar Cube: (a) 1 part ASTM Type II-V cement;(b) 1 to 2 parts silica sand; and (c) 0.4 to 0.5 parts water.

Looking next at the cross-sectional views in elevation of FIG. 5 andFIG. 10, when the vessel is used for storing wines, flavor imparting oakstaves 80 (or other flavor imparting substances) may be immersed in thewine and left to steep for a period of time by suspending the staves ona hanger hooked to the top manway 32.

Accordingly, and as will be appreciated from the foregoing detaileddescription and the accompanying drawings, in its most essential aspectthe present invention is a liquid storage vessel, especiallywell-adapted for use in wine storage, and includes a base with a bottomand an interior floor. A continuous side extends vertically from thebase and has an interior surface. The bottom and the continuous sideeach include an internal layer and an external layer separated by amaterial barrier. The layers are configured such that the interiorlayers form a continuous inner containment liner, and the externallayers form a continuous exterior structural shell enclosing the innercontainment liner. A top is bonded to the continuous side and has aninterior ceiling. One or more manways provide access to the tankinterior. Mounting and connecting structures enable the tanks to bestacked directly atop one another and then structurally connected. Apreferred material for the exterior structural shell is a highperformance fiber reinforced concrete. The inner containment liner isfabricated from a geopolymer concrete blend.

The foregoing disclosure is sufficient to enable those with skill in therelevant art to practice the invention without undue experimentation.The disclosure further provides the best mode of practicing theinvention now contemplated by the inventor.

What is claimed as invention is:
 1. A stackable liquid containmentvessel, comprising: a base having a bottom with an interior floor; acontinuous side extending generally vertically from said base and havingan interior surface; said bottom and said continuous side each includingan internal layer and an external layer configured in such a way thatsaid interior layers form a continuous inner containment liner definingan interior liquid storage volume, and said external layers form acontinuous exterior structural shell enclosing said inner containmentliner; a vessel top disposed atop said continuous side and having aninterior ceiling; at least one access manway located on said top or onsaid continuous side of said vessel; and mounting structure on said basefor placement on ground so as to create a ground clearance underneathsaid bottom; wherein said exterior structural shell is fabricated from ahigh performance fiber reinforced concrete, and said inner containmentliner is fabricated from a cast concrete blend.
 2. The stackable liquidcontainment vessel of claim 1, wherein said high performance fiberreinforced concrete is glass fiber reinforced concrete.
 3. The stackableliquid containment vessel of claim 1, wherein said cast concrete blendincludes milled dry earth components having low loss on ignition, loworganic and low heavy metal content.
 4. The stackable liquid containmentvessel of claim 3, wherein said dry earth components are milled to arange of approximately 200 mesh to approximately 450 mesh.
 5. Thestackable liquid containment vessel of claim 5, wherein said dry earthcomponents of said cast concrete blend include volcanic pumice,diatomaceous earth/siliceous shale, volcanic ash, calcium carbonate,silica, kaolinite clay, ultra-fine fired claybisque, soda lime glass,calcium sulfate hemihydrate, and lime kiln dust.
 6. The stackable liquidcontainment vessel of claim 5, wherein said dry earth components furtherinclude type F fly ash, type C fly ash, rice hull ash, and blast furnaceslag.
 7. The stackable liquid containment vessel of claim 1, including amanway disposed on said top, and wherein said mounting structurecomprises pair of legs having a height dimension sufficient toaccommodate forklift forks and to provide clearance for opening saidmanway on a lower vessel when a second vessel is stacked atop the lowervessel.
 8. The stackable liquid containment vessel of claim 7, whereinsaid legs are reinforced to approximate the interface between said legsand floor or a supporting stackable liquid containment vessel below. 9.The stackable liquid containment vessel of claim 1, further including atleast one access port disposed on said continuous side.
 10. Thestackable liquid containment vessel of claim 1, further including upperand lower embedded threaded receivers disposed on upper and lowerportions of said vessel sides to accept threaded fasteners and to serveas anchor points for connecting stacked vessels to one another withcoupling plates and securing said vessel to the floor with tie-downplates.
 11. The stackable liquid containment vessel of claim 1, whereinsaid vessel ceiling slopes upward to minimize head space above thestored liquid.
 12. A stackable wine storage tank, comprising: an innercontainment liner made from a cast concrete blend and forming aninterior storage volume; an exterior structural shell enclosing saidinner containment liner so as to form a two-layered vessel including afront side, right and left sides, a rear side, and a bottom side, saidexterior shell made from a fiber reinforced concrete; a base integralwith said bottom side; a top disposed on said vessel and having a slopedinterior ceiling; a manway disposed on said top or on said front side; adrain port disposed on a front side proximate said bottom side of saidvessel; and coupling structure for connecting stacked vessels.
 13. Thestackable wine storage tank of claim 12, further including a pluralityof access ports for the insertion of liquid sensors, probes and flavorsubmersibles, and for the removal of liquid from said vessel, or theintroduction of liquid into said vessel, after being stacked with othervessels.
 14. The stackable wine storage tank of claim 12, wherein saidcast concrete blend is a combination of milled dry earth components,alkaline reactive components, solutions of inorganic alkaline salts,silica sand, and water.
 15. The stackable wine storage tank of claim 16,wherein said dry earth components include volcanic pumice, diatomaceousearth/siliceous shale, volcanic ash, calcium carbonate, silica,kaolinite clay, fired clay bisque, soda lime glass, calcium sulfatehemihydrate, and lime kiln dust.
 16. The stackable wine storage tanks ofclaim 17, wherein said dry earth components further include type F flyash and type C fly ash, rice hull ash, and blast furnace slag.
 17. Thestackable wine storage tank of claim 12, further including legs disposedunder said base so as to provide ground clearance and tank clearancebetween stacked tanks for forklift and stored product access.
 18. Thestackable wine storage tank of claim 19, wherein said legs arereinforced and approximate the interface between said legs and floor orsupporting stackable wine storage tank below.
 19. The stackable winestorage tank of claim 12, further including connection structure tocouple stacked tanks to one another, said connection structurecomprising upper and lower embedded threaded receivers disposed on upperand lower portions of said vessel sides with which to connect stackedvessels using coupling plates.
 20. The stackable wine storage tank ofclaim 12, wherein said manway includes a cover pivotally attached tosaid top so as to pivot on a horizontal plane onto and away from themanway hole.